ELECTRICAL AND IGNITION

2
B

BATTERY, CHARGING SYSTEM and

STARTING SYSTEM
Table of Contents
Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-1
Operating Outboard without Battery . . . . . . 2B-1
Specific Gravity Readings . . . . . . . . . . . . . . 2B-1
Specific Gravity Cell Comparison Test . 2B-2
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . 2B-2
Charging a Discharged Battery . . . . . . . . . . 2B-2
Winter Storage of Batteries . . . . . . . . . . . . . 2B-3
Battery Charging System . . . . . . . . . . . . . . . . . . 2B-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-3
Battery Charging System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 2B-4
Stator Test (Alternator Coils Only) . . . . . . . 2B-4
Voltage Regulator Test . . . . . . . . . . . . . . . . . 2B-5
Alternator System Test . . . . . . . . . . . . . . . . . 2B-5
Manual Start Models – Stator Output
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-5
Electric Start Models With Rectifier . . . . 2B-5
Electric Start Models With Voltage
Regulator/Rectifier . . . . . . . . . . . . . . . . 2B-6
Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-7
Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Starter System Components . . . . . . . . . . . . 2B-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-8
Troubleshooting the Starter Circuit . . . . . . . 2B-8
Starter Circuit Troubleshooting Flow
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-9
Starter Removal and Installation . . . . . . . . . . 2B-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-10
Bosch Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-11
Starter Cleaning, Inspection and Testing . . . 2B-12
Cleaning and Inspection . . . . . . . . . . . . . . . 2B-12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-12
Armature Test for Shorts . . . . . . . . . . . . 2B-12
Armature Test for Ground . . . . . . . . . . . 2B-12
Checking Positive Brushes and
Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Testing Negative Brushes for Ground
(Bosch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2B-13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2B-14
Starter Solenoid Test . . . . . . . . . . . . . . . . . . 2B-16

2B-0 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Battery Operating Outboard without Battery
If desired (or in an emergency), outboards equipped
Precautions with an alternator can be started and operated with-
When charging batteries, an explosive (hydrogen) out a battery (either disconnected or removed) if
gas mixture forms in each cell. Part of this gas es- “Warning”, below, is followed.
capes thru holes in vent plugs and may form an ex-
plosive atmosphere around battery if ventilation is WARNING
poor. This explosive gas may remain in or around Before operating outboards with battery leads
battery for several hours after it has been charged. disconnected from battery, the leads MUST BE
Sparks or flames can ignite this gas and cause an in- taped off (insulated) or positioned in a manner
ternal explosion which may shatter the battery. that prevents a completed circuit between the
The following precautions should be observed to pre- leads. Electric wiring harness MUST REMAIN
vent an explosion. CONNECTED to electric starting models in order
to “Stop” the outboard with the ignition key.
1. DO NOT smoke near batteries being charged or
which have been charged very recently.
2. DO NOT break live circuits at terminals of batter- Specific Gravity Readings
ies because a spark usually occurs at the point
where a live circuit is broken. Always be careful Use a hydrometer to measure specific gravity of elec-
when connecting or disconnecting cable clamps trolyte in each cell.
on chargers. Poor connections are a common
cause of electrical arcs which cause explosions.
3. DO NOT reverse polarity of battery terminals to
cable connections.
4. If battery is still connected to outboard DO NOT
operate any outboard or boat electrical systems
that are powered by the battery, while charging
the battery.

CAUTION
If battery acid comes into contact with skin or
eyes, wash skin immediately with a mild soap.
Flush eyes with water immediately and see a doc-
tor.

WARNING
Hydrogen and oxygen gases are produced dur-
ing normal battery operation or charging. Sparks 22532
or flame can cause this mixture to ignite and ex-
plode, if they are brought near the battery. Hydrometer measures percentage of suplhuric acid
Sulphuric acid in battery can cause serious in battery electrolyte in terms of specific gravity. As a
burns, if spilled on skin or in eyes. Flush or wash battery drops from a charged to a discharged condi-
away immediately with clear water. tion, acid leaves the solution and enters the plates,
causing a decrease in specific gravity of electrolyte.
An indication of concentration of electrolyte is ob-
tained with a hydrometer.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-1

When using a hydrometer, observe the following Electrolyte Level
points:
Check electrolyte level in battery regularly. A battery
1. Hydrometer must be clean (inside and out) to in- in use in hot weather should be checked more fre-
sure an accurate reading. quently because of more rapid loss of water. If elec-
2. Never take hydrometer readings immediately af- trolyte level is found to be low, then distilled water
ter water has been added. Water must be thor- should be added to each cell until liquid level rises
oughly mixed with electrolyte by charging for at approx. 3/16” (4.8mm) over plate. DO NOT OVER-
least 15 minutes at a rate high enough to cause FILL because this will cause loss of electrolyte and
vigorous gassing. result in poor performance, short life and excessive
corrosion.
3. If hydrometer has built-in thermometer, draw liq-
uid in several times to ensure correct tempera-
ture before taking reading.
CAUTION
During service, only distilled water should be
4. Hold hydrometer vertically and draw in just
added to the battery, not electrolyte.
enough liquid from battery cell so that float is free-
floating. Hold hydrometer at eye level so that float Liquid level in cells should never be allowed to drop
is vertical and free of outer tube, then take read- below top of plates, as portion of plates exposed to
ing at surface of liquid. Disregard curvature air may be permanently damaged with a resulting
where liquid rises against float stem due to capil- loss in performance.
larity.
5. Avoid dropping electrolyte on boat or clothing, as
it is extremely corrosive. Wash off immediately Charging a Discharged Battery
with baking soda solution. The following basic rule applies to any battery charg-
Specific gravity of electrolyte varies not only with per- ing situation:
centage of acid in liquid but also with temperature.As 1. Any battery maybe charged at any rate (in am-
temperature drops, electrolyte contracts, so that spe- peres) as long as spewing of electrolyte (from vi-
cific gravity increases. Unless these variations in olent gassing) does not occur and as long as
specific gravity are taken into account, specific grav- electrolyte temperature does not exceed 125° F
ity obtained by hydrometer may not give a true indica- (52° C). If spewing of electrolyte occurs, or if elec-
tion of concentration of acid in electrolyte. trolyte temperature exceeds 125° F, charging
A fully charged battery will have a specific gravity rate (in amperes) must be reduced or temporarily
reading of approximately 1.270 at an electrolyte tem- halted to avoid damage to the battery.
perature of 80° F (27° C). If electrolyte temperature 2. Battery is fully charged when, over a 2-hour peri-
is above or below 80° F, additions or subtractions od at a low charging rate (in amperes), all cells
must be made in order to obtain a hydrometer read- are gassing freely (not spewing liquid electro-
ing corrected to 80° F standard. For every 10° F (3.3° lyte), and no change in specific gravity occurs.
C) above 80° F, add 4 specific gravity points (.004) to Full charge specific gravity is 1.260 - 1.275, cor-
hydrometer reading. Example: A hydrometer reading rected for electrolyte temperature with electrolyte
of 1.260 at 110° F (43° C) would be 1.272 corrected level at 3/16” (4.8mm) over plate, unless, electro-
to 80° F, indicating a fully charged battery. lyte loss has occurred (from age or over-filling) in
For every 10° below 80° F, subtract 4 points (.004) which case specific gravity reading will be lower.
from the reading. Example: A hydrometer reading of For most satisfactory charging, lower charging
1.272 at 0° F (-18° C) would be 1.240 corrected to 80° rates in amperes are recommended.
F, indicating a partially charged battery.

SPECIFIC GRAVITY CELL COMPARISON TEST

This test may be used when an instrumental tester is
not available. To perform this test, measure specific
gravity of each cell, regardless of state of charge, and
interpret results as follows: If specific gravity read-
ings show a difference between highest and lowest
cell of .050 (50 points) or more, battery is defective
and should be replaced.

2B-2 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

3. If, after prolonged charging, specific gravity of at
least 1.230 on all cells cannot be reached, battery WARNING
is not in optimum condition and will not provide Hydrogen and oxygen gases are produced dur-
optimum performance; however, it may continue ing normal battery operation or charging. Sparks
to provide additional service, if it has performed or flame can cause this mixture to ignite and ex-
satisfactorily in the past. plode, if they are brought near the battery.
4. To check battery voltage while cranking engine Sulphuric acid in battery can cause serious
with electric starting motor, place red (+) lead to burns, if spilled on skin or in eyes. Flush or wash
tester on positive (+) battery terminal and black away immediately with clear water.
(–) lead of tester on negative (–) battery terminal.
If the voltage drops below 9-1/2 volts while crank-
ing, the battery is weak and should be recharged Battery Charging System
or replaced.
Description
Winter Storage of Batteries The battery charging system components are the al-
ternator, rectifier and battery. Alternating current
Battery companies are not responsible for battery (generated in alternator coils) flows to the rectifier,
damage either in winter storage or in dealer stock if which changes the alternating current to direct cur-
the following instructions are not observed: rent for charging the battery.
1. Remove battery from its installation as soon as
possible and remove all grease, sulfate and dirt
from top surface by running water over top of bat-
tery. Be sure, however, that vent caps are tight
beforehand, and blow off all excess water thor-
oughly with compressed air. Check water level,
making sure that plates are covered.
2. When adding distilled water to battery, be ex-
tremely careful not to fill more than 3/16” (4.8mm)
over plate inside battery. Battery solution or elec-
trolyte expands from heat caused by charging.
Overfilling battery will cause electrolyte to over-
flow (if filled beyond 3/16” over plate).
3. Grease terminal bolts well with Quicksilver 2-4-C a - Alternator
Multi-Lube and store battery in COOL-DRY b - Rectifier
place. Remove battery from storage every 30-45 c - Battery
days, check water level (add water if necessary), The charging system may be damaged by: 1) re-
and put on charge for 5 or 6 hours at 6 amperes. versed battery cables, 2) running the engine with bat-
DO NOT FAST CHARGE. tery cables disconnected and cable ends touching
4. If specific gravity drops below 1.240, check bat- each other, 3) an open circuit, such as a broken wire
tery for reason and recharge. When gravity or loose connection, and 4) shorting across the bat-
reaches 1.260, discontinue charging. To check tery terminals.
specific gravity, use a hydrometer, which can be
purchased locally.
5. Repeat preceding charging procedure every
30-45 days, as long as battery is in storage, for
best possible maintenance during inactive peri-
ods to ensure a good serviceable battery in
spring. When ready to place battery back in ser-
vice, remove excess grease from terminals (a
small amount is desirable on terminals at all
times), recharge again as necessary and reinstall
battery.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-3

Battery Charging System Stator Test (Alternator Coils Only)
Troubleshooting
A fault in the battery charging system usually will
cause the battery to become undercharged. Check
battery electrolyte level, and charge battery. See
“Electrolyte Level”, and “Charging a Discharged Bat-
tery”, preceding.
If battery will NOT accept a satisfactory charge, re-
place battery.
If battery accepts a satisfactory charge, determine
the cause of the charging system problem as follows:
Visually check the following:
NOTE: Stator can be tested without removing from
1. Check for correct battery polarity [red cable to engine.
positive (+) battery terminal]. If polarity was incor-
1. Disconnect both yellow (stator leads).
rect, check for damaged rectifier. See “Rectifier
Test”, following. 2. Use an ohmmeter and perform the following test.
2. Check for loose or corroded battery connections. 3. Replace stator if readings are outside ranges
shown.
3. Visually inspect wiring between stator and bat-
tery for cuts, chafing; and disconnected, loose, or
STATOR TEST (BLACK STATOR)
corroded connections.
9 AMP Stator (398-818535A5)
4. Excessive electrical load (from too many acces-
sories) will cause battery to run down. Ohm Ohm
Test Leads To –
Scale Reading
If visual inspection determines that battery connec-
YEL and YEL Rx1 .8-1.1
tions and wiring is OK, perform the following stator
and rectifier test: 9 AMP Stator (398-8778A_)
Ohm Ohm
Test Leads To –
Scale Reading
YEL and YEL Rx1 .5-1.0
16 AMP Stator (398-9710A33 & 398-9710A42)
Ohm Ohm
Test Leads To –
Scale Reading
YEL and YEL Rx1 .10-.50

STATOR TEST (RED STATOR)

Electric Start Engines 9 Amp Stator
Ohm Ohm
Test Leads To –
Scale Reading
YEL and YEL Rx1 .4–1.0
Electric Start Engines 16 Amp Stator
Ohm Ohm
Test Leads To –
Scale Reading
YEL and YEL Rx1 0.165–0.181
Manual Start Engines
Ohm Ohm
Test Leads To –
Scale Reading
YEL and YEL Rx1 0.17–0.19

2B-4 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Voltage Regulator Test ELECTRIC START MODELS WITH RECTIFIER

b
LAMPS BURN OUT WHEN ENGINE IS REVVED
UP
The voltage regulator is defective. Replace voltage a - Rectifier
regulator. b - Red Lead
IMPORTANT: Rectifier must be functioning prop-
LAMPS BURN DIM AT WIDE-OPEN-THROTTLE erly for accurate test results to be obtained.
Run outboard at midrange (approximately 3000 1. Remove RED lead from (+) terminal of rectifier.
RPM) with 3 number 94 lamps connected to voltage
regulator output leads. Note lamp brightness. 2. Connect RED (+) ammeter lead to rectifier (+) ter-
minal and BLACK (–) ammeter lead to RED recti-
Disconnect the leads at tone terminal of regulator. fier lead.
Connect the leads together using a screw and nut.
Isolate (tape) connection. 3. With engine running at the indicated RPM, the
ammeter should indicate the following approxi-
Run outboard at midrange (approximately 3000 mate amperes:
RPM) and note lamp brightness. If lamps are consid-
erably brighter than with leads connected to regula- RPM AMPERES
tor, the regulator is defective. If lamps are NOT con- Idle 6
siderably brighter, check the alternator (refer to 9 Amp
Black Stator 1000 7
“Stator Test”, previously).
2000 8
3000 8
Alternator System Test

MANUAL START MODELS – STATOR OUTPUT

RPM AMPERES
TEST 9 Amp
Red Stator Idle 5
The stator that comes with manual start models is
NOT designed to produce its rated amperage at low (Used with Fly-
Fly
1000 8
wheels having
engine speeds (to charge batteries) but rather as a Magnets Installed
power source for running lights. However, if a rectifier 2000 9.5
p y
With Epoxy
kit is installed on the engine to enable the stator to 3000 10.0
charge a battery, the following approximate output
can be checked at the listed RPM with an in–series
ammeter:
9 Amp RPM AMPERES
RPM AMPERES Red Stator Idle 3.5
Idle 0 (Used with Fly
Fly-
Manual Start wheels having 1000 5.5
Stator 1000 0
Magnets Installed
2000 7
2000 6 With Retaining
g
Ring 3000 7.5
3000 9
4. If proper ampere readings are not obtained, re-
place stator.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-5

ELECTRIC START MODELS WITH VOLTAGE REG- 6. Connect RED (+) ammeter lead to larger diame-
ULATOR/RECTIFIER ter RED lead, and BLACK (–) ammeter lead to
POSITIVE on starter solenoid.
7. With engine running at the indicated RPM, the
ammeter should indicate the following approxi-
b mate amperes:
d
RPM AMPERES
Idle 6
9 Amp
1000 7
c Black Stator
2000 8
3000 8

RPM AMPERES
e
Idle 3
1000 10
a 16 Amp
A 2000 17
Black Stator
3000 18
a - Voltage Regulator/Rectifier
4000 18.5
b - Red Lead (Smaller Diameter)
c - Red (Larger Diameter) 5000 18.5
d - 9 Volt Transistor Battery
e - Connect Ammeter Between Red Leads
RPM AMPERES
1. Check battery voltage at battery with engine run-
Idle 2
ning.
1000 7
2. If battery voltage is above 14.5 volts, replace volt- 16 Amp
A
age regulator/rectifier. Check condition of battery 2000 15.5
Red Stator
as overcharging may have damaged battery. 3000 17
3. If battery voltage is below 14.5 volts, charge bat- 4000 17.5
tery. If battery can not be satisfactorily charged, 5000 18
replace battery.
8. If ammeter reads less than required amperes,
4. If cranking voltage is acceptable, disconnect the
test the stator. If stator tests OK, replace voltage
two red leads coming from the voltage regulator/
regulator/rectifier.
rectifier.
5. Connect the smaller diameter red lead to the (+)
terminal of a 9 volt transistor battery. Connect the
negative (–) terminal of the 9 volt battery to en-
gine ground.

2B-6 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Rectifier Test NOTE: Rectifier can be tested without removing from
engine.
WARNING 2. Disconnect all wires from terminals on rectifier.
Disconnect battery leads from battery before 3. Use an ohmmeter (R x 1000 scale) and perform
testing rectifier. the following test.
1. To gain access to rectifier, remove 6 bolts from d
a c
electrical box cover and remove cover.

a
f
b

e
07300
b a - Terminal
b - Terminal
c - Terminal
d - Alternator Terminals
e - Positive Terminal
54645
f - Ground
a - Bolts
b - Cover Connect red meter lead to ground, black lead alternately
to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated.

Connect black meter lead to ground, red lead alternately Connect black meter lead to ground, red lead alternately
to terminals “a” and “c”. to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated.

Connect black meter lead to terminal “b”, red Replace rectifier.
lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated.

Replace rectifier. Connect black meter lead to terminal “b”, red
lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated.

Connect red meter lead to terminal “b”, black Replace rectifier.
lead alternately to terminals “a” and “c”.

Continuity Indicated. No Continuity Indicated.

Replace rectifier. Connect red meter lead to terminal “b”, black
lead alternately to terminals “a” and “c”.

No Continuity Indicated. Continuity Indicated. No Continuity Indicated. Continuity Indicated.

Rectifier tests O.K. Replace rectifier. Replace rectifier. Rectifier tests O.K.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-7

Starter System Troubleshooting the Starter Circuit
Starter System Components Before beginning the starter circuit troubleshooting
flowchart, following, check first for the following
The starter system consists of the following parts: conditions:
1. Battery. 1. Make sure that battery is fully charged.
2. Starter motor solenoid. 2. Check that shift control lever is in “neutral” posi-
3. Neutral start switch. tion.

4. Starter motor. 3. Check terminals for corrosion and loose connec-

tions.
5. Ignition switch.
4. Check cables and wiring for frayed or worn in-
sulation.
Description
5. Check fuse in red wire.
The function of the starting system is to crank the out-
board. The battery supplies electrical energy to crank The following “Starter Circuit Troubleshooting Flow
the starter motor. When the ignition switch is turned Chart” is designed as an aid to troubleshooting the
to “Start” position, the starter solenoid is activated starter circuit. This flow chart will accurately locate
and completes the starter circuit between the battery any existing malfunction.
and starter. Location of “Test Points” (called out in flow chart on
The neutral start switch opens the starter circuit when next page) are numbered below.
the shift control lever is not in neutral. This prevents
accidental starting when engine is in gear.

CAUTION
The starter motor may be damaged seriously if
operated continuously. DO NOT operate continu-
ously for more than 30 seconds. Allow a 2 minute
cooling period between starting attempts.

Starter Circuit

2B-8 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

 Starter Circuit Troubleshooting Flow Chart
Starter Motor Does Not Turn

SAFETY WARNING: Disconnect yellow (starter motor) cable from starter solenoid
test Point 1 BEFORE making tests 1 thru 7 to prevent unexpected engine cranking.

TEST 1 Use an ohmmeter (R x 1 scale) and connect meter leads between negative
(–) battery post and common powerhead ground.

No Continuity Indicated Continuity Indicated

There is an open circuit in the black negative (–) battery cable Proceed to TEST 2.
between the negative (–) battery post and the powerhead.
a. Check cable for loose or corroded connections.
b. Check cable for open circuit.

TEST 2 12 Volt Reading*

No voltage reading; a. Disconnect black ground wire from Test Point 2. Check black ground wire for poor
proceed to TEST 3. b. Connect voltmeter between common engine connection or open circuit. reconnect
ground and Test Point 2. ground wire to starter solenoid;
c. Turn ignition key to “Start” position. proceed to TEST 7.

TEST 3
12 Volt Reading*
a. Reconnect black ground wire.
No voltage reading; Defective starter motor
b. Connect voltmeter between common engine
proceed to TEST 4. solenoid.
ground and Test Point 3.
c. Turn ignition key to “Start position.

TEST 4 12 Volt Reading*

No voltage reading; a. Connect voltmeter between common Neutral start switch is open, or
proceed to TEST 5. engine ground and Test Point 4. yellow/red wire is open between
b. Turn ignition key to “Start” position. Test Points 4 and 3.

No voltage reading; TEST 5 12 Volt Reading*

proceed to TEST 6. Connect voltmeter between common Defective ignition switch.
engine ground and Test Point 5.
12 Volt Reading*
Check fuse (if equipped) in red
No voltage reading; TEST 6 wire between test points 5 and
check red wire Connect voltmeter between common 6. Check for open red wire
between battery (+) engine ground and Test Point 6. between Test Points 5 and 6.
positive and Test
Point 6.

TEST 7 12 Volt Reading*

No voltage reading; a. Connect voltmeter between common Should hear solenoid click;
defective starter engine ground and Test Point 1. proceed to TEST 8.
solenoid. b. Turn ignition key to “Start” position.

TEST 8 12 Volt Reading*

No voltage reading; a. Reconnect yellow (starter motor) If starter motor does not turn,
check yellow cable cable to starter solenoid Test Point 1. check that starter motor is
for poor connection b. Connect voltmeter between common grounded to powerhead. If
or open circuit. engine ground and Test Point 7. starter motor is grounded to
c. Turn ignition key to “Start” position. powerhead, check starter.

TEST POINTS *Battery Voltage

Refer to preceding page
for Test Point location.

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-9

Starter Removal and Installation
Installation 1. Install collars on starter motor, if removed.
2. Connect BLACK ground cable to starter using
Removal bolt and lockwasher, if removed. Torque bolt to 85
lb. in. (9.6 N·m).
WARNING
Before working on outboard, disconnect battery
leads from battery and high tension leads from
spark plugs.
1. Disconnect battery leads form battery and high
tension leads from spark plugs.
2. Disconnect BLACK positive cable from starter a
motor.
3. Remove two upper mounting bolts, lockwashers
and BLACK ground cable from upper starter
mounting clamp. Remove clamp. b
4. Remove two bottom mounting bolts, lockwash-
ers, BLACK ground cable and BLACK ground
wire. Remove lower mounting clamp.
5. Lift starter motor from outboard.

c
a
54653

a - Collars
d b - Black Ground Cable
3. Install starter motor to outboard using upper and
lower mounting clamps and four mounting bolts.
Secure BLACK ground cables and BLACK
a ground wire under heads of mounting bolts.
e Torque bolts to 180 lb. in. (20.3 N·m).
h 4. Connect BLACK positive (+) cable to starter mo-
tor. Torque nut to 70 lb. in. (7.9 N·m).
g
f

54652

a - Black Positive Cable

b - Upper Mounting Bolts
c - Black Ground Cable
d - Upper Mounting Clamp
e - Bottom Mounting Bolts
f - Black Ground Cable (from Battery)
g - Black Ground Wire (Starter Motor Solenoid Ground)
h - Lower Mounting Clamp

2B-10 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Bosch Starter 5. Remove armature (along with drive end cap)
from starter frame.
Disassembly 6. If necessary, remove parts from armature shaft
by first removing locknut. Then remove parts
1. Remove starter as outlined in “Starter Removal
from shaft.
and Installation”, preceding.
2. Remove 2 thru bolts from starter.

a
b
54654
a
a - Thru bolts
b - Commutator End Cap
3. Tap commutator end cap to loosen and remove
from starter frame. Be careful not to lose brush
springs.
4. Brush replacement is recommended if brushes
are pitted, chipped or worn to less than 1/4”
(6.4mm). If necessary, remove brushes as fol-
lows: 11659
a. Lift brush holder from end cap. Remove hex a - Place Wrench on Hex Portion of Drive Assembly.
nut and washers from positive terminal and Removing Locknut
remove positive brushes (along with positive
terminal) as an assembly.
e
a b g
c f

b d
a c
d d

b a 11658

a - Locknut
b - Spacer
c - Spring
d - Drive Assembly
11656
e - Drive End Cap
a - Brush Holder f - Armature Shaft
b - Negative Brushes g - Washer
c - Positive Brushes Parts Removed from Armature Shaft
d - Positive Terminal

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-11

Starter Cleaning, Inspection 10. Repair bars, that are not too badly burned, by re-
soldering the leads in bars (using rosin flux sol-
and Testing der) and turning down the commutator in a lathe
to remove burned material, then undercut the
Cleaning and Inspection mica.
1. Clean all starter motor parts. 11. Clean out the copper or brush dust from slots be-
tween the commutator bars.
2. Check pinion teeth for chips, cracks or excessive
wear. 12. Check the armature for ground. See the following
procedure (“Testing”).
3. Replace the drive clutch spring and/or collar if
tension is not adequate, or if wear is excessive.
4. Check that the brush holder is not damaged or is Testing
not holding the brushes against the commutator.
ARMATURE TEST FOR SHORTS
5. Replace brushes that are pitted or worn to less
than 1/4” (6.4mm) in length. Check armature for short circuits by placing on growl-
er and holding hack saw blade over armature core
6. Replace a damaged or excessively worn bushing while armature is rotated. Recheck after cleaning be-
in the end cap. tween commutator bars. If saw blade still vibrates, re-
7. Check the armature conductor (commutator bar place armature.
junction) for a firm connection. A poor connection
usually results in a burned commutator bar.
8. Resurface and undercut a rough commutator, as
follows:

CAUTION
Do not turn down the commutator excessively.
a. Resurface the commutator and undercut the
insulation between the commutator bars
1/32” (0.8mm) to the full width of the insula- 11669
tion and so that the undercut is flat.
Armature Tests for Shorts (Bosch)
b. Clean the commutator slots after undercut-
ting. ARMATURE TEST FOR GROUND
c. Sand the commutator lightly with No. 00 1. Set VOA meter to (R x 1 scale). Place one lead
sandpaper to remove burrs, then clean the of VOA meter on armature core or shaft and other
commutator. lead on commutator.
d. Recheck the armature on a growler for 2. If meter indicates continuity, armature is
shorts, as specified in the following proce- grounded and must be replaced.
dure (“Testing”).
9. Open-circuited armatures often can be saved
where an open circuit is obvious and repairable.
The most likely place for an open circuit is at the
commutator bars, as a result of excessively long
cranking periods. Long cranking periods over-
heat the starter motor so that solder in the con-
nections melts and is thrown out. The resulting
poor connections then cause arcing and burning
of the commutator bars.
11675

Armature Test for Ground (Bosch)

2B-12 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

Checking Positive Brushes and Testing Negative Brushes for Ground
Terminal (Bosch)
Set VOA meter to (R x 1 scale). Connect meter leads Set VOA meter to (R x 1 scale). Place one lead of the
between positive brushes. Meter must indicate full VOA on the negative brush and the other lead on the
continuity or zero resistance. If resistance is indi- end cap (bare metal). If the meter indicates NO conti-
cated, check lead to brush and lead to positive termi- nuity, replace the negative brush. Repeat this proce-
nal solder connection. If connection cannot be re- dure on the other negative brush.
paired, brushes must be replace.

a b

11674

a - Negative (–) Brushes

b - End Cap

11673

a - Positive (+) Brushes

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-13

Reassembly Positive Brushes Installed

1. If brushes were removed, replace as follows:

a. Install positive brushes (along with positive
terminals) into commutator end cap.
c
Positive Brushes Components

b a

11660

a - Positive (+) Terminal

b - Long Brush Lead
c - Push Lead into Slot

b. Install negative brushes (along with brush

holder).
a

Negative Brushes Installed

b
a c b
c

d
d
e
d
f
54656
a - Insulating Bushing
b - Positive (+) Terminal a
c - Insulating Washer
d - Flat Washer
e - Lockwasher b
f - Hex Nut

54655
a - Positive (+) Brushes
b - Negative (–) Brushes
c - Brush Holder
d - Bolts (Fasten Negative Brushes and Holder)

2B-14 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996

2. If removed, reinstall parts on armature shaft. Use 6. Lubricate bushing (located in commutator end
a new locknut and tighten securely on end of cap) with one drop of SAE 10W oil. DO NOT over-
shaft. lubricate.
3. Lubricate helix threads on armature shaft with a 7. To prevent damage to brushes and springs when
drop of SAE 10W oil. installing commutator end cap, it is recom-
mended that a brush retaining tool be made.
4. Lubricate bushing in drive end plate with a drop
of SAE 10W oil.
5. Position armature into start frame so that com-
mutator end of armature is at end of starter frame
where permanent magnets are recessed 1”
(25.4mm).

Brush Retainer Tool Dimensions

Brush Retaining Tool Layout (Full Size)

Side View (Full Size)

90-814676R1 DECEMBER 1996 ELECTRICAL AND IGNITION - 2B-15

8. Place springs and brushes into brush holder and Starter Solenoid Test
hold in place with brush retainer tool.
Test starter solenoid as follows:
a 1. Disconnect all leads from solenoid terminals.
2. Using an ohmmeter (R x 1 scale), connect leads
between solenoid terminals 1 and 2, as shown.
3. Connect a 12-volt supply between solenoid ter-
minals 3 and 4, as shown. Solenoid should click
and meter should read zero ohms.
4. If meter does not read zero ohms (full continuity),
replace solenoid.

11661
a - Brush Retainer Tool
Brush Retainer Tool Installed on Commutator
End Cap
9. Install commutator end cap onto starter frame
align mark on frame with positive terminal and re-
move brush retainer tool. Install thru bolts and
torque to 70 lb. in. (7.9 N·m).

a
14354
a - 12-Volt Supply
b - Ohmmeter Leads

54657

a - Alignment Marks
b - Align Mark with Positive (+) Terminal

2B-16 - ELECTRICAL AND IGNITION 90-814676R1 DECEMBER 1996